Module with moment frame and composite panels for a building structure

ABSTRACT

A module for building structure includes a moment frame, a set of four top corner pieces, and a set of two or more composite panels. The moment frame is comprised of beams and columns jointed to form a top, a bottom and four sides. Each top corner piece is located at a corner of the top of the moment frame. The set of two or more composite panels is attached to the bottom of the moment frame to provide a sub-floor of the building structure. A first composite panel, of the set, is adapted to transfer a load to a second abutting composite panel of the set, in response to a deflection of the moment frame. Each composite panel is comprised of a core element encased in a metal frame, which includes two face sheets, two end cap pieces, and two side pieces.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application Ser.No. 61/131,957 filed Jun. 13, 2008, which is incorporated herein byreference in its entirety for all purposes.

BACKGROUND

1. Field

This application relates generally to modular building construction and,more specifically, to using a modular building moment frame to constructrapidly deployable structures that can be used to house or shelterpeople.

2. Description of the Related Art

Known methods of building construction can be used to provide homes,schools, medical facilities and other essential structures. Whiletraditional construction methods can be applied to a wide range ofapplications, traditional methods may require significant lead time, rawmaterials, and skilled labor resources.

For example, portions of a building structure may require customfabrication that must be performed at the building site. This presentsat least three constraints on a traditional construction project. First,it may be necessary to deliver large amounts of raw materials to thebuilding site. The raw materials must be stored, protected from theelements and secured from theft. Second, a skilled labor force may berequired to fabricate each element of the building structure using theraw materials provided. Foundations, walls, floors, ceilings and roofsmay be fabricated by hand and integrated into the building piece bypiece. Third, traditional methods may require a substantial lead timebetween the perceived need for a building and the completion of aworking facility. Traditional projects typically require time to design,draft, and procure materials before fabrication can begin. Planning andexecuting even a small construction project may require months ofadvanced planning. Large scale projects may require years.

The time constraints due to traditional methods may be unacceptable forprojects that require an accelerated build schedule. Traditional methodsmay also be unsuitable for projects with limited access to raw materialsor skilled labor. For example, exigent circumstances, such as militarytroop deployment, natural disaster relief, or population displacement,present immediate needs in areas that may be far removed fromtraditional construction resources.

In many cases, modular construction may overcome limitations oftraditional construction techniques. By prefabricating portions of thestructure off-site, lead time can be reduced, and fewer raw materialsmay be required on-site for the final construction. Prefabricatedmodules can be manufactured ahead of time, stored, and then shipped tothe final location once a facility is needed. Modules can also beconfigured on-site into a wide range of facilities and custom tailoredto the needs of the occupant. Additionally, modules designed tofacilitate on-site assembly may reduce the need for large numbers ofskilled construction workers.

What is needed is a modularized structural building system that can becustomized and manufactured in scalable quantities, and deployed worldwide.

SUMMARY

A module for building structure includes a moment frame, a set of fourtop corner pieces, and a set of two or more composite panels. The momentframe is comprised of beams and columns jointed to form a top, a bottomand four sides. Each top corner piece, of the set of four top cornerpieces, is located at each corner of the top of the moment frame. Eachtop corner piece has a coupler element to interface with a liftingmechanism that lifts the module. The set of two or more composite panelsis attached to the bottom of the moment frame to provide a sub-floor ofthe building structure. A first composite panel, of the set, is adaptedto transfer a load to a second abutting composite panel of the set, inresponse to a deflection of the moment frame. Each composite panel iscomprised of a metal frame having two face sheets, two end cap pieces,and two side pieces. The two face sheets are substantially parallel toeach other, the two end cap pieces are substantially perpendicular tothe face sheets, and the two side pieces are substantially perpendicularto both the face sheets and the end cap pieces. Each composite panel isfurther comprised of a core element encased within the metal frame, andbonded to the two metal face sheets.

DESCRIPTION OF THE FIGURES

FIG. 1A illustrates an exemplary embodiment of a building structurecomposed of multiple moment modules.

FIG. 1B illustrates an alternate embodiment of a building structurecomposed of multiple moment modules.

FIG. 1C illustrates a sectional cut-away view of a building structure,including a gable roof structure.

FIG. 2 illustrates a moment module.

FIG. 3 illustrates an interlocking panel joint.

FIG. 4 illustrates a moment frame.

FIGS. 5A to 5B illustrate 8×20 foot and 8×40 foot moment modules.

FIG. 6 illustrates a range of moment module sizes.

FIG. 7 illustrates a moment module with composite panels installed inboth the bottom and top of the moment frame.

FIG. 8 illustrates a type T moment module.

FIG. 9 illustrates a type-U moment module.

FIG. 10 illustrates a moment module with a single-pitch roof.

FIG. 11 illustrates a moment module with a double-pitch roof.

FIG. 12 illustrates a drainage system for a moment module.

FIG. 13 illustrates a moment module with side walls.

FIGS. 14A to 14H illustrate components of a composite panel assembly.

FIGS. 15A to 15H illustrate components of an alternative embodiment of acomposite panel assembly.

FIG. 16 illustrates the profile of an interlocking joint piece.

FIGS. 17A to 17C illustrate one embodiment of a face sheet.

FIGS. 18A to 18C illustrate an alternate embodiment of a face sheet.

FIGS. 19A to 19C illustrate one embodiment of an end cap.

FIGS. 20A to 20C illustrate an alternative embodiment of an end cap.

FIG. 21 illustrates an example of a flat pattern of an end cap.

FIG. 22 illustrates an example of mounting a composite panel using aledger configuration.

FIG. 23 illustrates an example of mounting a composite panel directly toa beam member.

FIGS. 24A and 24B illustrate an elevation view and detail view of alower frame corner.

FIGS. 25A and 25B illustrate an elevation view and detail view of anupper frame corner.

FIGS. 26A and 26B illustrate an elevation view and detail view of analternative upper frame corner.

FIGS. 27A and 27B illustrate a corner interface of four moment modulesin a building structure.

FIGS. 28A to 28F illustrate moment modules assembled into a buildingstructure.

FIG. 29 illustrates a three by three moment module structure.

FIGS. 30A to 30C illustrate alternative configurations of a buildingstructure using moment modules.

The figures depict one embodiment of the present invention for purposesof illustration only. One skilled in the art will readily recognize fromthe following discussion that alternative embodiments of the structuresand methods illustrated herein can be employed without departing fromthe principles of the invention described herein.

DETAILED DESCRIPTION

Modularized steel moment frames can be used to construct scalablebuilding structures for immediate deployment anywhere in the world. Thefollowing embodiments describe how different variations of a rapidlydeployable and stackable moment module (referred to simply as “momentmodule” hereafter) can be fabricated, shipped and assembled on-site tohelp create a variety of building facilities.

FIGS. 1A to 1C depict moment modules assembled together to form examplesof a building structure. In FIG. 1A, a 3 story building structure isformed using 3 stacks of 12 moment modules for a total of 36 momentmodules. As discussed in greater detail below, a moment module 100 canbe adapted in a variety of ways to form a completed building facility110. As shown in FIG. 1A, a moment module 100 can include stairs,external walls, windows and other traditional building features. FIG. 1Bdepicts another example of a building structure 120 featuring a fullyenclosed, internal stairway.

FIG. 1C depicts multi-story building 110 in a cut-away view. Asdiscussed in greater detail below, the moment module 100 allows for anopen span, which allows for a floor plan that is free from internalcolumns or load-bearing walls.

A completed building 110 may also include a gable roof structure 140.The gable roof structure 140 may be constructed using composite panelsor more traditional wooden truss construction and roofing materials. Theroof structure may also be constructed of a hybrid of composite panelsand traditional building materials. For additional descriptions ofcomposite panels being used to provide a roof structure, see U.S. Pat.No. 6,588,171, which is incorporated herein by reference in its entiretyfor all purposes. In alternative embodiments described herein, the roofstructure may also be integrated into individual moment modules thatmake up the top floor in a building.

1. Moment Module

As mentioned above, the moment modules can be used as the fundamentalstructural elements in a variety of building constructionconfigurations. Creating a building structure using moment modules, asdescribed herein, allows for a majority of the fabrication to beperformed off-site. The completed or partially completed moment modulescan then be shipped to the location of the building, and assembled intoplace. As depicted in FIGS. 2 to 13, moment modules can be constructedin a variety of configurations to provide features that are suited to aparticular application.

FIG. 2 is a perspective view of moment module 100, including a momentframe 210 and a set of two or more composite panels 220, which forms thefloor or sub-floor of moment module 100. In one alternative embodiment,a single composite panel may be used to form the floor or sub-floor. Inanother alternative embodiment, the floor or sub-floor is constructedusing materials that are not composite panels.

The moment frame 210 includes eight beams 212 and four columns 214,which are joined to form a top, bottom, and four sides. The four sidesof the moment module 100 can be left open because the columns 214 of themoment frame 210 can provide sufficient structural integrity withoutrequiring the use of load-bearing panels/walls.

In FIG. 2, two or more composite panels are attached to the bottom ofmoment frame 100. Each composite panel 220 may be attached using ledgerframe elements and threaded fasteners as described in more detail below.Once installed, the two or more composite panels become a structuralmember of the moment module 100. For example, in some embodiments, themoment module 100, including two or more composite panels, is able todistribute floor loads up to or in excess of 240 kg/m² (approximately 50lbs/ft²).

In some embodiments, the composite panels are able to distribute bendingor twisting loads exerted on the moment module. Because the compositepanels are physically integrated into the moment frame 210, thecomposite panels are able to resist a deflection or deformation in themoment frame. For example, each composite panel 220 (of the set ofcomposite panels) is able to resist a moment load, particularly if themoment load is perpendicular to a face sheet of the composite panel.(See section 3 below for a description of composite panel components.).By attaching the composite panel 220 to a beam 212 in the moment frame210, the composite panel 220 is able to impede a deflection of the beamby resisting the moment load created by the beam deflection. This isparticularly true for deflections that result in a moment that isperpendicular to the face sheet of the composite panel.

Thus, each individual composite panel 220 is able to provide additionalrigidity or structural support to the moment frame 210. In addition,each composite panel 220 is able to distribute loads to other, abuttingcomposite panels. For example, FIG. 3 depicts an exemplary embodiment ofan interlocking panel joint between abutting composite panels 220.

In some embodiments, the composite panels 220 may include interlockingjoint pieces along two sides of composite panel 220. Preferably formedfrom steel sheet, the interlocking joint pieces can be used to locateand support the composite panels 220 when they are installed in momentframe 210. FIG. 3 depicts an exemplary side detail of two compositepanels 220 joined together using interlocking joint pieces 234. In someembodiments, the interlocking joint pieces 234 may form the side pieceof the composite panel 220. For a detailed description of the compositepanel construction, see section 3, below.

Exemplary embodiments of the interlocking joint pieces 234 have aprotrusion shape 236 and a channel shape 238. Both shapes are formedinto the metal sheet and extend the length of the interlocking jointpiece. When assembled in the moment frame, the protrusion shape 236 ofthe interlocking joint piece can be inserted into the channel shape 238of another interlock joint piece, to form an interlocking panel jointbetween two abutting composite panels.

The interlocking panel joint resists relative movement of the compositepanels in at least the direction perpendicular to the joint. Forexample, if the panels are horizontal as shown in FIG. 3, the jointresists relative movement in the vertical direction. By resistingvertical motion, the joint is able to withstand sheer loads between thecomposite panels. For example, if the composite panels are used tocreate the floor of the moment module, the joint can support verticalsheer loads created by the weight of objects in contact with the floorof the moment module.

In a preferred embodiment, the protrusion shape 236 of the interlockingjoint piece is deeper than the channel shape 238 of a matinginterlocking joint piece so that there is a gap between the face sheetsof the two abutting composite panels. Depending on the strength of thematerial forming the protrusion shape 236, a compression load may betransferred from one composite panel to another, abutting compositepanel. For example, a compression load, substantially parallel to theface sheet of the composite panel and perpendicular to the panel jointmay be transferred from one composite panel to a second, abuttingcomposite panel.

In some embodiments, the panel joint may also resist torsional ortwisting loads between two composite panels. This may also increase therigidity of the moment module when a set of two or more composite panelsare installed in the moment frame. For example, if the moment frame issubjected to a torsional or twisting load, the beams in the moment framemay deflect or distort. As discussed above, this deflection may beresisted by each composite panel that is mounted to a deflecting framemember due to the rigidity or stiffness of each individual compositepanel.

Additionally, the moment frame deflection may be resisted due to thepanel joint between abutting pairs of composite panels. As the momentframe is distorted, a first composite panel may tend to shift withrespect to a second, abutting composite panel. The panel joint, however,resists this shifting by resisting relative movement of the twocomposite panels in a direction that is perpendicular or transverse tothe panel joint. By resisting this transverse motion, the two abuttingpanels are able to distribute a transverse load created by the framedistortion. Additionally, the panel joint may resist a movement of thecomposite panels in a direction that is substantially parallel to theface sheet of the composite panels and perpendicular to the panel joint.By resisting motion in this direction, the two abutting panels are ableto distribute a compression load created by the frame distortion. Thus,depending on the deflection of the moment frame, the panel joint maytransfer a compression load, a transverse load, or a combination of thetwo loads from a first composite panel to a second, abutting compositepanel.

In some embodiments, the panel joint connects a set of composite panelssuch that the combined and joined panels exhibit properties similar to asingle continuous panel. As described above, the panel joint may resistmotion of the composite panels in a direction parallel to the face sheetof the composite panel, and in a direction transverse or at an angle tothe face sheet of the composite panel.

The amount of rigidity or support created by the set of composite panelsmay also be reduced. Depending on the clearance between the mating facesin the joint, the panels may also be allowed to shift with respect toeach other to comply with a certain amount of deformation or planartwist in the moment module frame.

Note that FIG. 3 depicts the composite panels 220 horizontally mountedin a moment frame. However, various embodiments may use the compositepanels 220 with interlocking panel joints in other configurations or inconjunction with other elements of the structure, such as compositepanels used in a wall, ceiling or roof panel structure.

FIG. 4 depicts a perspective view of the moment frame 210 of the momentmodule 100 without composite panels. Four metal columns 214 are used toform the four sides of the moment frame. Eight metal beams 212 are usedto form the top and bottom of the moment frame. The metal beams andcolumns can be made of any structural grade steel or aluminum and mayeither be welded or connected using metal fasteners (e.g., bolts orrivets). Alternatively, the beams and columns could include differentcross sections or could be formed from metal sheet.

In some embodiments, the metal columns 214 may be made from a closedcross-section rectangular tube with a 150 mm×150 mm×9 mm cross-section.In some embodiments, the metal beams 212 may be made from a 200 mm×90mm×9 mm cross-section steel channel.

The moment frame includes four top corner elements attached to eachcorner of the top of the moment frame. In some embodiments, the momentframe may also include four bottom corner pieces attached to each cornerof the bottom of the moment frame. FIG. 4 depicts an embodimentincluding four top corner pieces 216 attached to the top of the momentframe and four bottom corner pieces 218 attached to the bottom of themoment frame. FIGS. 24-26 depict specific examples of corner pieceintegration in more detail.

Each top corner piece includes a coupler element to interface with alifting mechanism that lifts the module. For example, each top cornerpiece may include three external faces, with a slotted hole on eachface. The slotted holes project inward to a hollow core of the topcorner piece. In some embodiments, the top corner pieces may be designedin accordance with standard ISO freight container upper corner castings.

In some embodiments, the top corner pieces 216 can be used to lift orload the moment module during transportation. For example, if the topcorner pieces 216 are ISO corner castings, the module may be liftedusing existing crane and hoist equipment designed to move and transporttraditional cargo shipping containers.

Each bottom corner piece includes a coupler element to interface with asecuring mechanism that secures the module. For example, each bottomcorner piece may include three external faces, with a slotted hole oneach face. The slotted holes project inward to a hollow core of thebottom corner piece. In some embodiments, the bottom corner pieces maybe designed in accordance with standard ISO freight container lowercorner castings.

In some embodiments, the bottom corner pieces 218 can be used to securethe moment module to a deck or shipping platform. For example, if thebottom corner pieces 218 are ISO corner castings, the moment module maybe secured to the bed of a truck or deck of a boat designed to interfacewith traditional cargo shipping containers. Additionally, if the cornerpieces (top or bottom) are ISO corner castings, the moment module mayalso be stacked on top of or underneath a traditional cargo shippingcontainer. Similarly, the corner pieces (top or bottom) may also be usedto physically tie the moment module to another moment module.

FIGS. 5A and 5B depict examples of two different sizes for the momentmodule as moment modules 520 and 540, respectively. FIG. 5A depicts themoment module 520 as being approximately 9 feet, 6 inches tall by 8 feetwide by 20 feet long. The moment module 520 has approximately thedimensional footprint of a standard 8×20 cargo container. FIG. 5Bdepicts the moment module 540 as being approximately 9 feet, 6 inchestall by 8 feet wide by 40 feet long. The moment module 540 hasapproximately the dimensional footprint of a standard 8×40 cargocontainer. FIG. 6 depicts an end view and elevation view of a momentmodule with a range of sizes. While this range includes the preferredembodiments described in FIGS. 5A and 5B, the size of a moment modulemay include embodiments outside of the range of values shown in FIG. 6.In a preferred embodiment, the interior dimension of the moment moduleprovides a minimum 8 foot ceiling clearance. To provide for increasedceiling height, moment modules can be made to an external height of 11feet, 6 inches.

Because the moment modules 520 and 540 have approximately the samefootprint as standard cargo containers, they can be handled,transported, and/or relocated using existing transportation and handlingequipment available throughout the world. As described above, if amodule conforms to ISO specifications, the moment module can betransported using trucks, hoists, and ships that are used to transportstandard cargo containers. The moment modules can also be handled atbuilding sites and assembled using handling equipment adapted tointerface with standard cargo containers. In this way, moment modulescan be rapidly deployed throughout the world using existingtransportation infrastructure. It should be noted, however, that momentmodules can have various sizes and various shapes.

2. Moment Module, Configurations

A moment frame, composite panels and other structural elements may beintegrated to create various configurations of the moment module. Forexample, one or more composite panels can be used to construct themoment module floor, the moment module ceiling, the moment module roof,and/or the moment module walls. For a more detailed description of acomposite panel, see sections 3 below.

In the moment module 710 depicted in FIG. 7, a top set and a bottom setof two or more composite panels 220 are attached to the bottom and topof the moment frame 210 to form a sub-floor and a ceiling, respectively,of a building structure. Note, however, that the set of composite panelsattached to the bottom of the frame may differ from the composite panelsattached to the top of the frame.

As described earlier, a moment module may include only the first set oftwo or more composite panels attached to the bottom of the moment frameto provide a sub-floor of a portion of a building structure.Alternatively, a moment module may include only the second set of two ormore composite panels that can be attached to the top of the momentframe to provide a ceiling of a portion of a building structure. In someembodiments, a single composite panel can be used to provide either thesub-floor or ceiling of a building structure. In another alternativeembodiment, the moment module does not include any composite panels.

FIGS. 8 and 9 depict two types of moment modules. One moment module isreferred to herein as a type-T moment module 810, while the other isreferred to as a type-U moment module 910. As depicted in FIG. 8, thetype-T moment module 810 has composite panels attached to the top of themoment module with the top of the panels approximately flush with thetop of the top beams of the moment frame of the moment module. Thetype-T moment module 810 can be used for a single story building or asthe top floor of a multi-story building. As depicted in FIG. 9, thetype-U moment module 910 has composite panels attached to the top of themoment module with a space between the top of the panels and the top ofthe top beams of the moment frame of the moment module. The type-Umoment module 910 can be used as the lower unit in multi-storybuildings. In some embodiments, the spacing can be used for wires,plumbing, duct-work, etc.

FIGS. 10 and 11 depict moment modules with a single and double-pitchroof, respectfully. The slope of the pitched roof allows water to drainoff the building structure. FIG. 10 depicts moment module 1010 with asingle-pitch roof. In one exemplary embodiment, the pitch of the roofmay be approximately a 10 mm to 20 mm drop per meter length (⅛″ to ¼″drop per foot length). However, the pitch of the roof is typically aresult of the space available in the top of the moment frame. FIG. 11depicts an embodiment of a moment module 1110 using a double-pitch roofwith the highest point in the center of the moment module. Pitched roofelements may be made using composite panels, metal sheet or wood.

In one embodiment, the roof may be made from stamped corrugated steelsheet and then covered with a polyisocyanurate (PIR) extruded foamboard. The PIR board may then be covered with an ethylene propylenediene (EPDM) M-class synthetic rubber. Other embodiments may includealternative materials for insulating and waterproofing roofs. In someembodiments, support for the pitched roof may be provided by ledgerelements (described below) or cross beam support (not shown).Pitched-roof moment modules 1010 and 1110 may be used for a single storybuilding or as the top floor of a multi-story building.

In an alternate embodiment, the roof may be constructed using stampedcorrugated steel sheet. The steel sheet may be welded along the seams toprovide a waterproof barrier. The steel sheet may be installed toprovide a pitch, as described above. In alternate embodiments, the steelsheet may be preformed or installed to form a convex shape. This allowswater or other fluids to drain from the top of the moment module.

FIG. 12 depicts one embodiment of a roof drainage system. As shown inFIG. 12, a channel member 1112 may be used to support one end of thepitched roof. Alternatively, the pitched roof may be supported by ledgeror other frame elements. The portion of the frame above the roof is leftopen to allow water to flow without obstruction. In some embodiments, abeam member 1114 may be used above the open portion of the frame toincrease the strength of the top of the moment frame. In alternativeembodiments, the beam of the frame may have holes or slots that alsoallow for fluids to drain from the top of the moment module.

FIG. 13 depicts a walled moment module 1310. In some embodiments, thewalls 1320 of the moment module 1310 may include a set of one or morecomposite panels. Similar to the panels used floor of the moment module100 in FIG. 2, the wall panels may include interlocking panel jointelements. See also FIG. 3 for an example of an interlocking panel joint.In alternative embodiments, the side panels may be made from metalsheet. For example, a single metal sheet or several metal sheets may beattached to portions of the moment frame beam. Alternatively, side wallsmay also be constructed from traditional wall materials, including metalstuds, sheet rock and insulation.

In some embodiments, a rubberized sheet may be included in the side wallinstallation to provide a water-tight barrier. In some embodiments, theside walls are installed only for shipping and are removed before themoment module is assembled into a building structure. In otherembodiments, the panels are installed as permanent structural componentsof the frame.

3. Moment Module, Composite Panel Construction

As described above, moment modules may use various forms of a compositepanel to provide the floor, ceiling, walls or roofing of a buildingstructure. FIGS. 14A to 14H depict various views of an exemplarycomposite panel 220. FIGS. 15A to 15H depict an alternate compositepanel 250 that provides an end cap 262 with a flanged portion formounting.

As shown in FIG. 14F, the composite panel 220 includes a frame 230, acore element 222 and two face sheets 224. The core element 222 isencased in an outer skin. In particular, the core element 222 is bondedto each of the two face sheets 224. In one preferred embodiment, thecore element 222 is made of foam. For example, the core element 222 canbe an extruded polystyrene foam, such as an extruded polystyrene Type VIfoam plastic board with a nominal density of 29 kg/m³ (2.0 lb/f³). Itshould be noted, however, that the core element 222 can be made fromvarious materials, including, without limitation, cellular honeycombcores of various materials such as aramid fiber and resin impregnatedpaper, foam cores such as polyurethane or polystyrene (both EPS andXPS).

The core element 222 can be bonded to the two face sheets 224 using anadhesive, such as a Type II, Class 2, adhesive. For example, the coreelement 222 can be bonded to the two face sheets 224 using apolyurethane adhesive. It should be noted, however, that various typesof adhesives may be used.

In one exemplary embodiment, the adhesive is applied to the face sheets224, such as by spraying the adhesive onto the face sheets. The facesheets 224 with the adhesive applied are then pressed against the coreelement 222. This assembly can be heated under pressure to cure theadhesive. Temperature and curing conditions may vary according to theadhesive used. It should be noted that the composite panel can befabricated using various fabrication processes to bond the face sheets224 to the core element 222.

In one embodiment, the frame 230 includes two end cap pieces 232 and twointerlocking joint pieces 234. As described above, the interlockingjoint pieces 234 may be formed from a metal sheet to provide aprotrusion shape 236 and a channel shape 238. See FIG. 16 for anexemplary embodiment of the profile of an interlocking piece 234. Thisembodiment of an interlocking joint piece 234 may also be referred to asa side piece.

Additionally, two metal flanges may be formed into the interlockingjoint piece 234 so that the flanges can be inserted into a hem fold onthe face sheets 224. This particular embodiment allows the interlockingjoint pieces 234 to be physically connected to the face sheets 224without the use of fasteners or welds. However, in some embodiments, theinterlocking joint pieces 234 may also be spot welded to the face sheets224. The end cap pieces 232 may then be installed by attaching theflanges of the end cap pieces 232 to the interlocking joint pieces 234,using threaded fasteners.

When fully assembled, the two face sheets 224 are substantially parallelto each other. Additionally, the two end cap pieces 232 aresubstantially perpendicular to the face sheets 224, and the twointerlocking joint pieces 234 are substantially perpendicular to boththe face sheets 224 and the end cap pieces 232. The frame 230 and facesheets 224, together, form the outer skin of the composite panel. Insome embodiments, the frame and face sheets are made of galvanizedsteel.

FIGS. 17A to 17C depict the face sheet 224 used as both the top andbottom face sheets in the embodiment of the outer skin depicted in FIGS.14A to 14H. FIGS. 19A to 19C depict the end cap 232 used as the frontand back edge pieces in the embodiment of the outer skin depicted inFIGS. 14A to 14H. As depicted in FIG. 14E, in the present embodiment,the end of the metal frame is flush.

FIGS. 15A to 15H depict various views of another exemplary compositepanel 250. The present exemplary composite panel 250 differs from theexemplary composite panel depicted in FIGS. 14A to 14H in that the endcaps 262 are Z-shaped to have a portion that extends outward from theedge of the frame (see FIGS. 15E and 15H). The portion of the end capthat extends outward can be used to support or hang the panel whenmounted in a moment module. FIGS. 20A to 20C depict the z-shaped endcaps 262 in more detail. Note, as depicted in FIGS. 21A and 21B, the endcaps of the two exemplary composite panels can be formed from the sameblank 2100.

The top face sheet 266 of the present exemplary composite panel 250 mayalso differ from the top face sheet of the exemplary composite panel 220depicted in FIGS. 14A to 14H. The top face sheet of an alternativeembodiment of a composite panel is depicted in more detail in FIGS. 18Ato 18C.

For additional description of composite panels, see U.S. Pat. No.6,588,171, which is incorporated by reference in its entirety for allpurposes.

4. Frame and Panel Integration

As described above, composite panels may be installed in a moment moduleusing a variety of configurations. In some embodiments, composite panels220 are supported in the moment module frame 210 through the use ofledgers 270. With reference to FIG. 22, the beams 212 of the momentframe can include ledgers 270 used to support the composite panels 220.The ledger 270 depicted in FIG. 22 is an angle iron extrusion that iswelded to the beam 212 of the moment frame. Alternatively, a ledger maybe formed from any material that provides a shelf for mounting acomposite panel 220. For example, the ledger may be formed from sheetmetal or integrated into the beam extrusion profile. As depicted in FIG.22, the composite panel 220 can be attached to the ledgers 270 usingthreaded fasteners 272. For example, the threaded fastener may be aself-drilling, self-tapping threaded screw fastener. With reference toFIG. 23, a beam 212 without a ledger is depicted. In the embodimentillustrated in FIG. 23, the composite panel 220 is attached to the topof the beam using a threaded fastener 272.

It should be noted, however, that the composite panel can be attached tothe moment frame using various means. For example, some embodiments ofthe composite panel may include an outwardly extended flange formed fromthe end cap piece of the composite panel frame. See FIGS. 15A to 15H,for examples of a z-shaped end cap 262. In some embodiments, the flangeof the end cap can be secured to the moment frame using metal fasteners.

FIGS. 24 to 26 depict exemplary embodiments of the use of ledgers in amoment frame. FIGS. 24A and 24B depict a detail and elevation view of aledger element used to support a composite panel installed in the floorof the moment frame. In one embodiment, the ledger is welded to theframe elements as shown in FIG. 24A.

In FIGS. 25 and 26, a hollow structural section (HSS) is used to formthe ledger element. FIGS. 25A and 25B depict an embodiment of a type-Tmoment module 810 using ledger elements in the top of the moment frame.FIGS. 26A and 26B depict an embodiment of a type-U moment module 910using ledger elements in the top of the moment frame.

6. Modular Building Structures

A complete building structure can be designed and built using variationsof the moment module embodiments described above. Building momentmodules may be fabricated off-site in accordance with the final buildingspecifications and then shipped to the construction site for assembly.Alternatively, the moment modules may be customized once they arrive atthe building site or after they have been integrated into the buildingstructure.

FIGS. 27A and 27B depict a detail view of four moment modules joined attheir respective corners. FIG. 27A depicts a corner connection at thecorner of the frame of four moment modules without composite panels. Insome embodiments, the top and bottom corner elements 216, 218 may beused to support the main weight of the moment module frame. In someembodiments, the top and bottom corner elements are upper and lower ISOcorner castings, respectively. In other embodiments, the weight of themoment module frame may be distributed along frame members. Momentmodules may be joined by welding the portions of the frame that areadjacent to other moment module frame members. For example, a weld maybe placed on each of the meeting edges of the four corner elements 216,218. In alternative embodiments, a connecting plate or other connectinghardware may be used to join the corners of the frame. For example, insome embodiments, an ISO attachment bridge clamp can be used to tie themoment modules together.

FIG. 27B depicts a corner connection with the composite panels of themoment modules installed. As can be seen in FIG. 27B, a space is leftbetween the composite panel of a lower moment module, which would formthe ceiling of the lower moment module, and the composite panel of anupper moment module, which would form the floor of the upper momentmodule. As discussed earlier, this space can be used to run wires,plumbing, duct-work, etc.

FIGS. 28A to 28F depict structural elements of an exemplary 12 momentmodule building. FIG. 28A depicts a building without external walls orfacing material. FIG. 28B depicts a building without ceiling or roofelements. FIGS. 28C and 28D depict moment modules assembled together toform three separate building floors with an open span (i.e., no internalsupporting columns).

FIG. 28E depicts an embodiment of a single building level 2800 using 12moment modules 100. FIG. 28E illustrates how moment modules 100 can beused with different wall configurations to provide an enclosed space.For example, exterior walls 2810 can be used to provide a barrierbetween the interior of the building floor and outside weather orenvironmental elements. The exterior walls 2810 may include windows,doors, or other traditional design features. The external walls 2810 mayalso incorporate a protective facing material, such as vinyl siding,stucco or brick. Alternatively, the external walls 2810 may be wood,metal or composite and provide for the mounting of protective facingmaterials or facade. The building level 2800 may also incorporateinternal walls 2820 used to partition off space in the level or createseparate rooms. Note that it is not necessary for these exterior walls2810 or interior walls 2820 to provide structural or load-bearingsupport to the building level 2800. For example, several of the momentmodules 100 have an open span and do not require additional verticalsupport from walls or partitions.

FIG. 28F depicts an alternative embodiment of a building floor 2850including individual rooms 2860 and connecting hallway 2870. Because theinterior walls are not needed for structural support, the interior spaceof a building floor can be reconfigured or adapted to provide for aflexible floor design layout.

The building structures, illustrated in FIGS. 28A to 28F, are merelyexemplary embodiments that illustrate the use of a modular moment frameas a structural element in a building structure. Alternative embodimentsmay arrange moment modules in different configurations or incorporatemoment modules with other known construction elements.

FIG. 29 depicts moment modules 2920, 2930, and 2940 as structuralelements in a multi-story building 2910. In this configuration, lowermoment modules 2920 support the weight of upper moment modules 2930 and2940. Because the lower moment modules 2920 support a larger load, thelower moment modules 2920 may be constructed using different materialsor components than the upper moment modules 2930 and 2940. For example,the vertical column or horizontal beam members of the lower momentmodules may be larger and, therefore, able to support the additionalweight.

FIGS. 30A to 30C depict various examples of a moment module 100 used indifferent sized building structures. As discussed above, the componentsused in each of the moment modules may vary depending on the loadingconditions of the overall building structure. For example, momentmodules located on the lower levels or on the outside of the structuremay be designed to provide increased load-carrying capabilities.

FIGS. 30A to 30C further illustrate how the top panels of a lower momentmodule can be left open to create a higher ceiling height for aparticular story. Alternatively, the panels of the bottom of an uppermoment module can be left open to create additional ceiling height.

1. A module for a building structure comprising: a moment framecomprised of beams and columns joined to form a top, a bottom and foursides; a set of four top corner pieces, each top corner piece located ata corner of the top of the moment frame, each top corner piece having acoupler element to interface with a lifting mechanism that lifts themodule; and a set of two or more composite panels attached to the bottomof the moment frame to provide a sub-floor of the building structure,wherein a first composite panel of the set is adapted to transfer a loadto a second abutting composite panel of the set, in response to adeflection of the moment frame, wherein each composite panel comprises:a metal frame having two face sheets, two end cap pieces and two sidepieces, wherein the two face sheets are substantially parallel, the twoend cap pieces are substantially perpendicular to the face sheets, andthe two side pieces are substantially perpendicular to both the facesheets and the end cap pieces; and a core element encased within themetal frame, wherein the core element is bonded to the two metal facesheets.
 2. The module of claim 1, wherein each side piece is a metalsheet formed to create an interlocking joint piece, wherein theinterlocking joint piece includes a channel shape and a protrusion shapeextending the length of the interlocking joint piece.
 3. The module ofclaim 2, wherein the channel shape of an interlocking joint piece of thefirst composite panel interconnects with protrusion shape of theinterlocking joint piece of the second composite panel.
 4. The module ofclaim 3, wherein the interlocking joint piece is adapted to providevertical support for a second composite panel abutting the firstcomposite panel.
 5. The module of claim 3, wherein the interlockingjoint piece of the first composite panel is further adapted to transfera compression load to the second composite panel abutting the firstcomposite panel.
 6. The module of claim 3, wherein the composite panelsare adapted to support a compression load in response to the modulebeing subjected to a moment load.
 7. The module of claim 1, wherein themetal frame is made of steel, and wherein the core element is made offoam.
 8. The module of claim 1, further comprising, a second set of twoor more composite panels, wherein the second set of two or morecomposite panels is attached to the top of the moment frame to provide aceiling of the building structure.
 9. The module of claim 8, wherein thesecond set of composite panels that provide the sub-floor comprisesdifferent materials than the set of composite panels that provide theceiling.
 10. The module of claim 1, further comprising, ledgers attachedto at least two beams in the frame, wherein the set of two or morecomposite panels is attached to the ledgers.
 11. The module of claim 1,wherein the set of two or more composite panels provide the sub-floor ofa first module and the same composite panels provide a ceiling of asecond module, wherein the second module is mounted below the firstmodule.
 12. The module of claim 1, wherein each of the set of four topcorner pieces having a coupler element comprises: three external facesand three slotted holes, each slotted hole extending inward from each ofthe three external faces.
 13. The module of claim 1, wherein each of thefour top corner pieces is comprised of an ISO corner casting.
 14. Themodule of claim 1, further comprising, a set of four bottom cornerpieces, each bottom corner piece located at a corner of the bottom ofthe moment frame, each bottom corner piece having a coupler element tointerface with a securing mechanism that secures the module.
 15. Themodule of claim 14, wherein each of the set of four bottom corner pieceshaving a coupler element comprises: three external faces and threeslotted holes, each slotted hole extending inward from each of the threeexternal faces.
 16. The module of claim 14, wherein each of the fourbottom corner pieces is comprised of an ISO corner casting.
 17. Themodule of claim 1, wherein the bottom of the moment frame hasapproximately the footprint of a standard 8×20 cargo container.
 18. Themodule of claim 1, wherein the bottom of the moment frame hasapproximately the footprint of a standard 8×40 cargo container.
 19. Themodule of claim 1, wherein the bottom of the moment frame has an outsidewidth of approximately 8 feet and an outside length of about 20 feet.20. The module of claim 1, wherein the bottom of the moment frame has anoutside width of approximately 8 feet and an outside length of about 40feet.
 21. The module of claim 1, wherein the beams are comprised of asteel channel with a cross-section ranging between 150 mm to 250 mm inheight and between 60 mm and 120 mm in width.
 22. The module of claim 1,wherein the columns are comprised of a steel rectangular tube with across-section ranging between 120 mm to 180 mm in height and width. 23.The module of claim 1, further comprising, a roof panel section, whereinthe roof panel section includes one or more corrugated steel sheetpieces, each sheet piece welded along the edge to create a waterresistant seam.
 24. The module of claim 23, wherein the roof panelsection is formed into a convex shape to direct water to the edges ofthe module.
 25. The module of claim 1, further comprising, apitched-roof section, wherein the pitched roof includes at least oneflat panel piece and at least one weather resistant sheet attached tothe top of the flat panel piece.
 26. The module of claim 25, wherein theflat panel piece is a composite panel.
 27. The module of claim 25,wherein the pitched-roof section includes a single pitch of ⅛ inch riseper foot of length.
 28. The module of claim 25, wherein the pitched-roofsection includes a double-pitch section of ¼ inch rise per foot oflength, and wherein the top of the double-pitch section is in a centerof the module.
 29. The module of claim 1, wherein another set of two ormore composite panels form a side wall of the module.
 30. The module ofclaim 29, wherein a first composite panel of the set forming the sidewall interconnects with an abutting second composite panel of the setforming the side wall.
 31. A modular system for constructing a buildingstructure, comprising: two or more modules joined together to form aportion of the building structure, each module comprising: a momentframe comprised of beams and columns joined to form a top, a bottom, andfour sides; a set of four top corner pieces, each corner piece locatedat a corner of the top of the moment frame, each corner piece having acoupler element to interface with a lifting mechanism that lifts themodule; and a set of two or more composite panels attached to the bottomof the moment frame to provide a sub-floor of the building structure,wherein each composite panel comprises: a metal frame having two facesheets, two end cap pieces and two side pieces, wherein the two facesheets are substantially parallel, the two end cap pieces aresubstantially perpendicular to the face sheets, and the two side piecesare substantially perpendicular to both the face sheets and the end cappieces; and a core element encased within the metal frame, wherein thecore element is bonded to the two metal face sheets.
 32. The modularsystem of claim 31, wherein the two or more modules are joinedside-by-side to one another to form a portion of one story of thebuilding structure.
 33. The modular system of claim 31, wherein the setsof two or more composite panels of the two or more modules are attachedto the bottoms of the two or more modules, and wherein adjacent sides ofside-by-side modules are left open to create a clear span for thebuilding structure.
 34. The modular system of claim 31, wherein the twoor more modules are joined one on top of another to form multiplestories of the building structure.
 35. The module system of claim 34,wherein the two or more modules comprise: a first type of modules,wherein the first type of modules forms an upper most story of thebuilding structure, wherein the sets of two or more composite panels ofthe first type of modules are attached to the top of the moment framewith top metal face sheets of the sets of the two or more compositepanels being substantially flush with tops of the beams that form thetop of the first type of modules.
 36. A module for a building structurecomprising: a moment frame comprised of beams and columns joined to forma top, a bottom and four sides; a set of four top corner pieces, eachtop corner piece located at a corner of the top of the moment frame,each top corner piece having a coupler element to interface with alifting mechanism that lifts the module; and a set of four bottom cornerpieces, each bottom corner piece located at a corner of the bottom ofthe moment frame, each bottom corner piece having a coupler element tointerface with a securing mechanism that secures the module.